Makita DHS680 Common Problems & Fixes (With Spare Parts Guide)

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The Makita DHS680 18V brushless circular saw is a popular trade saw, but after heavy use certain parts naturally wear out. If your DHS680 has stopped working properly, the issue is often caused by a single replaceable component rather than the whole tool being faulty.

Below are the most common Makita DHS680 problems and the spare parts that usually fix them.

1. DHS680 Won’t Start

Symptoms:

• No power when trigger is pressed
• Battery is known to be good
• No sound from motor

Likely causes:

• Faulty switch assembly
• Damaged wiring
• Blown internal component

Fix:

The most common repair is replacing the trigger switch (Switch unit TG73BDS-2 / Makita part 650734-1).
This part controls power delivery from the battery to the motor and wears with heavy use.

✔ Check battery terminals
✔ Inspect wiring for breaks
✔ Replace switch unit if dead

2. Blade Spins but Has No Power

Symptoms:

• Blade turns but stalls in wood
• Weak cutting performance
• Burning smell

Likely causes:

• Worn or damaged blade
• Failing spindle bearing
• Debris inside gearbox

Fix:

Start with a new 165mm blade. If power is still low, inspect:

• Spindle (326459-6)
• Ball bearing 6001 (211131-2)

Worn bearings create drag and reduce cutting torque.

3. DHS680 Cuts Out While Cutting

Symptoms:

• Stops mid-cut
• Works again after cooling
• Intermittent running

Likely causes:

• Faulty switch
• Overheating protection activating
• Loose internal connection

Fix:

Replace the switch assembly and inspect internal wiring.
Clean vents and dust build-up around the motor housing to reduce overheating.

4. Blade Won’t Spin Freely

Symptoms:

• Blade feels stiff when turned by hand
• Grinding noise
• Excess vibration

Likely causes:

• Worn spindle
• Failed bearing
• Bent blade

Fix:

Remove blade and test spindle movement:

• Replace spindle (326459-6) if wobbling
• Replace bearing (6001DDW) if noisy
• Fit new blade

Ignoring this can lead to gearbox damage.

5. Guard Not Returning Properly

Symptoms:

• Blade guard sticks
• Doesn’t close fully
• Feels loose

Likely causes:

• Worn blade cover spring
• Damaged lower blade guard
• Dust build-up

Fix:

Clean pivot points first.
If still faulty, replace:

• Lower blade guard
• Return spring

A sticking guard is a serious safety issue and should not be ignored.

6. Excessive Vibration

Symptoms:

• Tool shakes badly
• Noisy operation
• Rough cuts

Likely causes:

• Bent blade
• Loose spindle bolt
• Worn bearing

Fix:

Check and replace:

• Blade
• Spindle bolt (266924-2)
• Ball bearing (6001DDW)

Vibration accelerates wear on all moving parts.

7. Dust Blowing Everywhere

Symptoms:

• Poor dust control
• Line of cut not visible
• No extraction connection

Likely causes:

• Missing or broken extraction nozzle

Fix:

Replace dust extraction nozzle (196961-1).
This restores airflow and improves cutting accuracy.

Most Common DHS680 Spare Parts

These are the parts most often replaced on the Makita DHS680:

• Switch assembly
• Blade
• Spindle
• Bearings
• Blade guard
• Guard spring
• Extraction nozzle
• Spindle bolt
• Base plate (if dropped)

These are all serviceable Makita DHS680 parts — meaning the saw is normally worth repairing.

Why Repairs Beat Replacing the Tool

Repairing your DHS680 using genuine spare parts:

✔ Costs far less than a new saw
✔ Keeps a professional tool in service
✔ Reduces downtime
✔ Maintains cutting accuracy
✔ Is environmentally better than replacement

Final Advice

If your Makita DHS680 is faulty, don’t assume the motor is dead.
In most cases, the issue is caused by:

• A worn switch
• A damaged spindle or bearing
• A safety component like the blade guard

All of these are replaceable using genuine DHS680 spare parts.